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Troy-Bilt Super Bronco 60TG Operator's Manual

Automatic lawn tractor
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Automatic Lawn Tractor-
Super Bronco TM(Model 60TG)
READ SAFETY
RULES
AND mNSTRUCTmONS CAREFULLY
BEFORE
OPERATION
Warning:
This unitis equippedwith an internalcombustionengineand shouldnot be usedon or nearany unimproved forest-covered, b rush=
coveredor grass=covered l and unlessthe engine'sexhaustsystemis equippedwith a sparkarrestermeetingapplicablelocalor state laws (if any),
If a sparkarresteris used, it shouldbe maintainedin effectiveworkingorder by the operator,Inthe Stateof Californiathe aboveis requiredbylaw
(Section4442 of the CaliforniaPublicResources Code), Otherstates mayhavesimilarlaws,Federallaws applyon federallands,A sparkarrester
for the muffleris availablethroughyournearestengineauthorizedservicedealeror contactthe servicedepartment,RO, Box361131 Cleveland,
Ohio 44136=0019,
FORMNO, 770=104901
PRINTEDIN U,S,A
Troy-Bilt
LLC, P.O. BOX 361131 CLEVELAND,
OHIO 44136-0019
1/06/2006

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Summary of Contents for Troy-Bilt Super Bronco 60TG

  • Page 1 If a sparkarresteris used, it shouldbe maintainedin effectiveworkingorder by the operator,Inthe Stateof Californiathe aboveis requiredbylaw (Section4442 of the CaliforniaPublicResources Code), Otherstates mayhavesimilarlaws,Federallaws applyon federallands,A sparkarrester for the muffleris availablethroughyournearestengineauthorizedservicedealeror contactthe servicedepartment,RO, Box361131 Cleveland, Ohio 44136=0019, FORMNO, 770=104901 PRINTEDIN U,S,A Troy-Bilt LLC, P.O. BOX 361131 CLEVELAND, OHIO 44136-0019 1/06/2006...
  • Page 2 This Operator's Manua_ is an important part of your new lawn tractor, mtwH_ he_p you assemble, prepare and maintain the unit for best performance. P_ease read and understand what it says. Table of Contents Slope Gauge ............Maintaining Your Lawn Tractor ......
  • Page 3 your lawn moweron such slopes. WARNING Do not mowon inclines with a dope in excess of 15 degrees (a rise of approximately 2-" feet). A riding r could overturn and cause serious injury. if operating a walb behind mower on such a dope, it is extremely footing and you could dip, resulting in serious...
  • Page 4 _ i _i i _ iii _ _ DANGER: This machine was built to be operated according to the rubs for safe operation in this manuak As with any type of power equipment, carelessness or error on the part of the operator can S ale result in serious injury.

  • Page 5: General Operation

    General Operation: 14.Watchfor traffic whenoperatingnearor crossing roadways. T his machineis not intendedfor useon 1. Read,understand,and followall instructionson the anypublic roadway. machineand in the manual(s)beforeattemptingto 15.Do notoperatethe machinewhileunderthe influ- assembleand operate.Keepthis manualin a safe enceof alcoholor drugs. placefor future and regularreferenceand forordering 16.Mowonly in daylightor good artificiallight.
  • Page 6 Do Not: Slope Operation: Slopesare a majorfactorrelatedto loss of controland 1, Do notturn on slopes unlessnecessary;then,turn slowlyand graduallydownhill,if possibb, tip-overaccidentswhich can resultin severeinjury or 2, Do not mownear drop-offs,ditchesor embankments, death,All slopesrequireextracaution,if you cannot The mowercouldsuddenlyturnoverif a wheel is over back up the slopeor if youfeel uneasyon it, do notmow the edgeof a cliff, ditch,or if an edge cavesin, 3, Do nottry to staNlizethe machineby puttingyourfoot...
  • Page 7 Service lO,Neverattemptto makeadiustmentsor repairsto the machinewhile theengine is running, 1. Neverrun an engineindoorsor in a poorlyventilated 11,Grasscatchercomponentsand the discharge area. Engineexhaustcontainscarbonmonoxide,an coverare subiectto wearand damagewhichcould odorless,and deadlygas. exposemovingpartsor allowobiectsto be thrown, 2. Beforecleaning,repairing,or inspecting,makecertain Forsafety protection,frequentlycheckcomponents the blade(s)and all movingparts havestopped. and replaceimmediately with originalequipment Disconnectthe sparkplug wireand groundagainstthe manufacturer's (O,E,M,)parts only,listed in this...
  • Page 8 Attaching Battery Cables NOTE:The positivebatteryterminalis markedPos, (+), The negativebatteryterminalis markedNeg, (-), • Thepositivecane (heavyred wire) is securedto the positivebatteryterminal(+)with a hexbolt and hex nut at thefactory,Beforeattachingthe negativecane removethe batteryby removingthe positivecane and hold-downstrap,Notethe dateon theside of the Hex Nut Hex Bolt battery,If the batteryis put into serviceafter this date, chargethe batteryas instructedin the Maintaining YourLawnTractorsectionof this manualprior to...
  • Page 9 Attaching Steering Whee_ The hardwarefor attachingthe stetting wheelhasbeen packedwithin thesteeringwheel,beneaththe steering wheelcap, Carefullypry off the steeringwheelcapand removethe hardware, NOTE:Thereare two differentstylesof steeringwheel cap, See Figure3, Styles vary by model. 1. With the wheels of the tractor pointing straight forward, placethe steeringwheeloverthe steering shaft, 2, Placethe washer(with thecuppedside down)over the steeringshaftand securewith the hex bolt, See...

  • Page 10: Know Your Lawn Tractor

    Know Your Lawn Tractor NOTE: Any reference in this manual to the RBGHT or LEFT side of PTO(BladeEngage)Lever CruiseControIButton Ammeter IgnitionSwitchModule ParkingBrakeButton BrakePedal ShiftLever Drive Pedal Cup Holder DeckLift Lever Throttb Lever NOTE:Anyreferencein this manualto the RIGHTor LEFTside of the tractoris observedfrom operator'sposition,...
  • Page 11 of the engineand whenpushedall the wayforward,the chokecontrolalso, Whenset in a given position,the Position throttlewill maintaina uniformenginespeed,See Figure IMPORTANT: W henoperatingthetractorwith the cutting deck engaged,be certainthat the throttb bver is always in the FAST(rabbit)position, Choke Control Movingthethrottle bver all theway Slow _> forwardactivatestheengine'schoke Position control Activatingthe chokecontrol...
  • Page 12 PTO (B_ade Engage} Lever i-6--I AMPS OFF, / BLADE ENGAGE The PTO(BladeEngage)leveris locatedon the left side of the dashboardnext to the steeringwheel Movethe PTO(Blade Engage)leverforwardto engagethe powerto the cuttingdeck or other(separatelyavailable)attach- ments;movethe PTO(Blade Engage)leverrearwardto disengagethe powerto theattachments. NOTE:The PTO(Blade Engage)levermust be in the Figure 8 disengaged(OFF) positionwhenstartingthe engine, Ammeter...
  • Page 13 Thecruise controlbutton is locatedon the tractordash leverin the engaged(ON)position,regardless of whetherthe parkingbrakeis engaged, panelto the left of the ignition switch,Pushthe cruisecontrol With the ignitionkey in the NORMALMOWING buttonwhiletravelingforwardat a position,the enginewillautomaticallyshut off if the desiredspeed,While holdingthe PTO(BladeEngage)leveris movedintothe engaged buttonin, releasepressurefrom (ON) positionwith the shift leverin Reverse, the drivepedal This will engage the cruisecontroland allowthe...
  • Page 14 Reverse ndicator .Push Button AVOID SERIOUS INJURY OR DEATH Light Reverse GO UPAND DOWN SLOPES,NOT ACROSS, AVOIDSUDDENTURN& Stop CautionMod_ Position Position DO NOT OPERATETHE UNITWHERE IT COULDSLIP ORTIR Start IF MACHINE STOPSGOINGUPHILL,STOP BLADE(S) AND Position BACK DOWNHILLSLOWLY DO NOT MOWWHEN CHILDRENOR OTHERS AREAROUND, NEVER CARRYCHILDREN,EVENWITH BLADES OFE LOOK DOWNAND BEHINDBEFOREAND WHILE BACKING.
  • Page 15 NOTE:The deck wheelsare an anbscalp featureof the 1, If the bladesare engaged,placethe PTO(Blade deck and are notdesignedto supportthe weightof the Engage)leverin thedisengaged(OFF)position, cuttingdeck, 2, Turnthe ignitionkeycounterclockwise to the STOP Referto Leveling the Deck on page 18of this manual position, for moredetailedinstructionsregardingvariousdeck 3, Removethe key from the ignitionswitchto prevent adiustments, unintendedstarting,...
  • Page 16 !'!! /"q Driving On S_opes Tochangeto the reversedirectionwhenoperatingwith / A E Referto the SLOPEGAUGEon page3 to helpdeter= cruisecontrol,depressthe brakepedalto disengagethe ///_ mineslopeswhereyou mayoperatethe tractorsafely, cru,secontroland bnngthe tractortoe completestop, Thenplacethe shift leverin the REVERSE positionand WARNING: Do not mow on thedrive depress pedal, inclines with a slope in excess...
  • Page 17 WARNING: PJan yourmowing patternto avoiddischarge of materials towardroads,side° waJks, bystanders andthe like. Nso, avoid discharging material against a wall or obstruction which may cause discharged materiaJ to ricochet back toward the operator. Do not mowat high groundspeed,especiallyif a mulchkit or grasscollectoris installed, For bestresultsit is recommended that the firsttwo lapsbe cut with the dischargethrowntowardsthe center,After thefirst two laps, reversethe directionto...
  • Page 18 properadiustmentand proceed,if necessary,to the next step. 3. Loosenthe two iam nuts,if present,on the rear sideof the deck stabilizerbracket. 4. Locatethe lock nut on the front sideof the stabilizer bracket.See Figure11.Tightenthe lock nutto raise the frontof thedeck; loosenthe lock nut to lowerthe front of the deck.
  • Page 19 2, Loosen,but do NOTremove,the hex nutfoundon the rightsideof the brakeassembly,See Figure13, 3, Usinga feelergauge,set the gap betweenthe brake disc and the brakepuck at ,011", 4, Reqightenthe hexnut loosenedearlier, Seat Adjustment WARNING: Before operating this machine, make sure the seat is engaged in the seat stop, stand behind the machine and pull back on seat until fully engaged intostop.
  • Page 20 6, Refillthe enginewith newmotoroil as instructedin the KohlerOperator/Owner M anualpackedwith your unit, IMPORTANT: R eferto the KohlerOperator/Owner Manualpackedwith yourunit for informationregardingthe quantityand properweightof motoroil Air Cleaner Servicethe pre=cbaner,if so equipped,and cartridge/air cbaner elementas instructedin the Kohbr Operator/ OwnerManualpackedwith your unit, Spark PJug(s) Thespark plug(s)shouldbe cleanedand the gap reset oncea season,Sparkplug replacementis recommended...
  • Page 21 Deck Wash System Yourtractor'sdeck may be equippedwith a waterport on its surfaceas part of its deck wash system, If equipped,usethe DeckWashSystem to rinsegrass clippingsfromthe deck'sundersideand preventthe buildupof corrosivechemicals,Completethe following stepsAFTEREACHMOWING: 1, Drivethe tractorto a level,clearspot on yourlawn, near enoughto a water sillcock(spigot)for your gardenhoseto reach, IMPORTANT: M akecertain thetractor'sdischargechute is directedAWAYfrom yourhouse,garage,parkedcars,...
  • Page 22 WARNING: Batteries give off an fromthe deck lift arm, explosive gas while charging. 7, Rotatethe pin slightlytowardthe rear of the tractor Charge battery in a well ventilated and releasethe pin intothe hob provided, area and keep away from an open 8, Repeattheabovestepson thetractor'srightside, flame or pilot light as on a water 9, Movethe deck lift bver intothe top notchon the right...

  • Page 23: Cutting Blades

    Cutting Blades WARNING: Besuretoshut the engine off, remove ignition key, disconnect the spark plug wke(s) and ground against the engine to prevent unintended starting before removing the cut- ting Made(s} for sharpening or replacement. Protect your hands by using heavy gloves or a rag to grasp the cutting Made.
  • Page 24 3, Removethe beltguardsby removingthe self-tapping screwsthat fastenthem to the deck, 4, Carefullyloosen,butdo not remove,the deck idler WARNING: Be sure to shut pulleys, the engine off, remove ignition 5, Removethe deck belt fromaroundall pulleys,including key, disconnect the spark plug the deck idler pulleys, wire(s) and ground against the 6, Routethe newbelt as shownin Figure23 and retighten engine to prevent unintended...
  • Page 25 42" Deck LeftHand inePulley SpindlePulley Right Hand Spindle Pulley IdlerPulleys Figure 23...

  • Page 26: Attachments & Accessories

    of this manualbeforestoringfor an extendedperiod, Manualfor properenginecare prior to storingyourtractor, WARNING: Never store the WARNING: Drain fueJ only into machine or fuel container indoors an approved container outdoors, away from an open flame. Allow where there is an open flame, engine to coot.
  • Page 27 NOTE: I_ BOTA MODES, _HE_ _pE_ATOR LEAVES _EAT, EfiG]N_WILL out importantsafety instructionswhich, if not followed,couUd endangerthe personal safetyand/or property d yourselfand others. Read and follow aH instructionsin this manual beforeat- temptingto operate this machine, FaiBre to complywith these instructionsmay result in personalinjury,When yousee this symbol, HEED iTS WARNING!
  • Page 28 Problem Cause Remedy 1. PlacePTOknob (or lever)in 1, Unit runningwith CHOKEapplied, 1, PushCHOKEcontrol(if so Engine runs erratic equipped)in, or movethe throttle For repairs beyond controlout of the CHOKEposition, 2, Sparkplug wire(s) loose, the minor adjust- 2, Connectand tightenspark ments listed here, plugwire(s), contact an authorized 3, Cban fuel line;fill tank with clean,...
  • Page 29 Problem Cause Remedy 2, Air flow restrbted,' 2, CLean grassclippingsand debris aroundthe engine:scoe!!ng • • fins and bbwer housing. Enginehesitates at 1, Sparkplug(s)gap tooclose, 1, Removespark plug(s)and reset high RPM thegap, ..equipped, ..... Excessive 1, Cuttingblade looseor unbalanced, 1, Tightenbladeand spindle,Balanc( blade, Vibration...
  • Page 30 Model 60TG Modelsw/Manually Adjusting Seat Models w/Quick Adjust Seat ..¸¸¸•' (iii _ii_i i _'i! ¸ •...
  • Page 31 Ref. Part No. Description Ref. Part No. Description 710-1268t Screw,#10-16x.375 783-0677B Adiust.Brkt., Lift 712-04063 Nut, FlangeLock,5/16-18,GrF 783-1489B MountingBracket,Seat 710_0227 Screw,#8_18 x.50 712-3027t Nut, FlangeLock, 1/4-20 720-0309At SeatAdiusterGrip 726_0279 Plate,Insulator 726-0201t Nut, Speed,.3125 ID 725_1303 SpringSwitch,Outer 731-04074f Spacer 725-1439 SpringSwitch,inner 726_0278 Plate,InsulatorBoss 732-0499t Compression Spring.41x 1.5...
  • Page 32 Model 60TG...
  • Page 33 Ref. Part No. Description 710-04095 Hex Screw,3/8-16, 1,00,Gr5 710-0514 Hex Screw,3/8q6, 1,00,Gr5 710-0843 Hex Screw,5/16q8, 1,00,Gr5 711q408 Link, Drag,RH 711q409A Link, Drag,LH 712-0214 Nut, Hex Lock,3/8-24 712-04065 Nut, FlangeLock,3/8q6, Grf 712-0459 Nut, FlangeLock,7/16-20 712-3004A Nut, FlangeLock,5/16q8, Gr5 10 712-0240 Nut,Jam,7/16-20,Gr2 11 717q550E Gear,Steering,11/90Ratio 12 717q554 Gear,Pinion,Steering...
  • Page 34 Mode_ 60TG...
  • Page 35 Fief. Part No. Ref. Part No. Description Description 710-0728 731-1857 ThrottleControlKnob Screw,5/16-12x.750 710-0599 731-05001A DashPanel Self-tappingScrew,1/4-20x.5 783-04829 Side Panel- LH 731-04729 CruiseControl Button 746-1084 ThrottleControl/Cable 731-04728 ParkingBrakeButton 731-1999 747=04161 ChokePlug Tank SupportRod 731-05357 747=1196 Brake/Cruise Pivot Rod HeadlightLens 738-04091 ShoulderScrew.43x.29 629-04083t Headlight W ire Harness 783-04827...
  • Page 36 Model 60TG Left Hand Transmission Bolt Mounting...
  • Page 37 Ref. Part No. Description Ref. Part No. Description 17840 MountingBracket,Transaxle 783-04360 Bracket,Shift,F-N-R 725-04039 Switch,Interlock 783-04442 Idler Bracket,CenterDouble 17962 Plate,Switch 647-0031B ControlAssembly,Brake 647-04020 LeverAssembly,Shift 647-0032A ControlAssembly,Speed 710-0607 Screw,5/16-18, 0 .500 683-0266 PedalAssembly 710-0726 Screw,5/16-12, 0 .750 710-0650 Screw,5/16-18,0.875 710-0809 Screw,1/4-20,1.250 710-1260A Screw,5/16-18, 0.750 710-1007 Screw,Seres,3/8-16, 1.500...
  • Page 38 Model 60TG Ref. I Part No. Description 656=04015 PulleyAss'y,VariableSpeed 84 683=04129 Bracket,Pulley 710=0627 Screw,5/16=24,.750 710=1652 Screw,1/4=20,.625 87 718=04012 Cup, Bearing 736=0362 Washer,Flat 741=0600 Ball Bearing 783=04722 SwitchBracket,ParkingBrake 736=0242 Washer,Bell.340x.872x.060 712=04065 Nut,FlangeLock,3/8=16,GrF _FACTORY PARTS 710=0599 Screw,1/4=20x.500 736=0430 FlatWasher.350x 1.59x.062 634=0104 WheelAssyComp,20 x 8 x 8 734=1730 Tire Only20 x 8 x 8 To order replacement...
  • Page 39 _"_!_*'_"_'_*'_S_°,°_ ustrat Exhaust gasket, f_)_ mountingnuts,and starter nut supplied _FACTORY PARTS by Kohler To order replacement parts, call _heCustomer Service Line at 1o800-648-6776, or visit www.troybilt.com. Ref. Part No. Ref. Description Part No. Description 710-0227 AB Screw#8-18x 0,5 726-0272 Clamp 710-0599 TT Screw1/4-20x 0,5 751-3140...
  • Page 40 Mode_ 60TG IMPORTANT For a proper working machine, Jse Factory Approved Parts. 7-beltsare designed to _ngageand disengage safely. substitute (non OEM) Wbeit sanbe dangerous by not Jisen a in corn_letel.
  • Page 41 Ref. Rof.po, ,o. Do,c,p ioo po, ,o. Do,c,p ioo 17962 Plate,Switch 756=04196 Pulley,Engine,3.39x 6.12Dia. 647=04036 LeverAssembly,Engagement 783=0744A Stop Bracket,Engagement 710=0778 Screw,1/4=20x 1.500 683=04173 FrameAssembly,Lower 710=0859 Screw,3/8=16, 2 .50 710=0607 Screw,5/16=18, 0 .500 710=0276 Screw,Carriage,5/16=18, 1 .00 710=0642 Screw,1/4=20, 0 .750 710=1260A Screw,5/16=18 x.750 710=3005 Screw,3/8=16,1.25,Gr5...
  • Page 42 Model 60TG...
  • Page 43 Ref. Part No. Description 732-0614 Ring,Wire 716-0231 Ring,E Type.750 736-0336* FlatWasher,5/8x 1.0x.030 736-0337* FlatWasher,5/8 x 1.0x.040 736-0349* FlatWasher,5/8 x 1.0x.020 736-0335 Washer,Thrust.635x 1.26x.06 710-1325 Self-tapping Screw,1/4-20x 1.625 719-04017 UpperRousing 711q109 input Shaft 741-0335 NeedleBearing.625x.813x.495 _FACTORY PARTS 717-1464 144oothBevelPinion 716-0108 RetainingRing.437 741-0340 SleeveBearing.75x.1.0x 1.0 721-0338...
  • Page 44 Mode_ 60TG il 7}...
  • Page 45 Ref. Part No. Description Ref. Part No. Description 618=0624 SpindleAssembly,Pul,6,23" Dia 736=0300 Washer,Flat,,406x ,875x ,059 683=04138A BrakeAssembly,Deck 736=0760 Washer,Lock 737=04003C DeckWater Nozzle 683=04261 DeckShell,42" 683=04167 BrakeAssembly,Deck 738=04166 Spacer,Shoulder,,5000x,1475 683=0254B Brkt,Ass'y,Deck, HangerLH 721=04041 WaterNozzleAdapter 710=3015 Screw,1/4=20, , 75, Gr5 738=04162A Spacer,Shoulder,,8840x,190 710=0654A Screw,3/8=16,1,00 742=0616A Blade,21,23",Star3=in=l 710=0528...
  • Page 46 Use this page to make notes andwritedown important information.
  • Page 47 CAUFORNJA EMiSSiON CONTROL WARRANTY STATEMENT YOUR WARRANTY RIGHTS AND OBLIGATIONS The CaliforniaAir ResourcesBoardand MTDConsumerGroupInc are pleasedto explainthe evaporativeemissioncontrolsystemwarrantyon your2006 lawn mower.In California,new lawnmowermust be designed,built andequippedto meet the State'sstringentanti-smogstandards.MTD ConsumerGroupInc must warrantthe EECSon your lawnmowerfor the periodof time listedbelow providedthere has beenno abuse,neglector impropermaintenanceof your lawnmower. YourEECSmay includeparts such as the carburetor,fuel-injectionsystem,the ignitionsystem,catalyticconverter,fuel tanks,fuel lines,fuel caps, valves, canisters,filters,vapor hoses,clamps,connectors,and otherassociatedemission-related components.

  • Page 48: Limited Warranty

    Troy-Bilt. During the installationor use ofany part, accessoryor attachmentnot approvedby period of the warranty, the exclusive remedy is repair or replacement Troy_Bilt f or use with theproduct(s)coveredby this manualwill voidyour of the product as set forth above.